Kohler XT675 Engine Full Service Repair Manual

1 14 690 01 Rev. G KohlerEngines.com XT-6, XTR-6, XT6.5, XT650, XT6.75, XT675, XT-7, XTR-7, XT775, XT8 Service Manual 2 Safety 3 Maintenance 5 Speciﬁcations 10 Tools and Aids 13 Troubleshooting 17 Air Cleaner/Intake 18 Fuel System 24 Governor System 26 Lubrication System 27 Electrical System 31 Starter System 33 Disassembly/Inspection and Service 45 Reassembly IMPORTANT: Read all safety precautions and instructions carefully before operating equipment. Refer to operating instruction of equipment that this engine powers. Ensure engine is stopped and level before performing any maintenance or service.

2 Safety KohlerEngines.com 14 690 01 Rev. G SAFETY PRECAUTIONS WARNING: A hazard that could result in death, serious injury, or substantial property damage. CAUTION: A hazard that could result in minor personal injury or property damage. NOTE: is used to notify people of important installation, operation, or maintenance information. WARNING Explosive Fuel can cause fires and severe burns. Do not fill fuel tank while engine is hot or running. Gasoline is extremely flammable and its vapors can explode if ignited. Store gasoline only in approved containers, in well ventilated, unoccupied buildings, away from sparks or flames. Spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition. Never use gasoline as a cleaning agent. WARNING Rotating Parts can cause severe injury. Stay away while engine is in operation. Keep hands, feet, hair, and clothing away from all moving parts to prevent injury. Never operate engine with covers, shrouds, or guards removed. WARNING Carbon Monoxide can cause severe nausea, fainting or death. Avoid inhaling exhaust fumes. Engine exhaust gases contain poisonous carbon monoxide. Carbon monoxide is odorless, colorless, and can cause death if inhaled. WARNING Accidental Starts can cause severe injury or death. Disconnect and ground spark plug lead(s) before servicing. Before working on engine or equipment, disable engine as follows: 1) Disconnect spark plug lead(s). 2) Disconnect negative (–) battery cable from battery. WARNING Hot Parts can cause severe burns. Do not touch engine while operating or just after stopping. Never operate engine with heat shields or guards removed. WARNING Cleaning Solvents can cause severe injury or death. Use only in well ventilated areas away from ignition sources. Carburetor cleaners and solvents are extremely flammable. Follow cleaner manufacturer’s warnings and instructions on its proper and safe use. Never use gasoline as a cleaning agent. CAUTION Electrical Shock can cause injury. Do not touch wires while engine is running. CAUTION Damaging Crankshaft and Flywheel can cause personal injury. Using improper procedures can lead to broken fragments. Broken fragments could be thrown from engine. Always observe and use precautions and procedures when installing flywheel. WARNING Uncoiling Spring can cause severe injury. Wear safety goggles or face protection when servicing retractable starter. Retractable starters contain a powerful, recoil spring that is under tension. Always wear safety goggles when servicing retractable starters and carefully follow instructions in Retractable Starter for relieving spring tension.

3 Maintenance 14 690 01 Rev. G KohlerEngines.com MAINTENANCE INSTRUCTIONS WARNING Before working on engine or equipment, disable engine as follows: 1) Disconnect spark plug lead(s). 2) Disconnect negative (–) battery cable from battery. Accidental Starts can cause severe injury or death. Disconnect and ground spark plug lead(s) before servicing. Normal maintenance, replacement or repair of emission control devices and systems may be performed by any repair establishment or individual; however, warranty repairs must be performed by a Kohler authorized dealer. MAINTENANCE SCHEDULE After first 3-5 Hours ● Change oil. Lubrication System Every 25 Hours or Annually¹ ● Service/replace precleaner. Air Cleaner/Intake ● Check air cleaner for dirty, loose or damaged parts. Air Cleaner/Intake Every 50 Hours or Annually ● Change oil. Lubrication System ● Replace fuel filter (if equipped). Every 50 Hours or Annually¹ ● Replace air cleaner element. Air Cleaner/Intake Every 100 Hours or Annually¹ ● Clean spark arrestor (if equipped). Every 100 Hours or Annually² ● Have combustion chamber decarbonized. Every 125 Hours or Annually¹ ● Replace spark plug and set gap. Electrical System 1 Perform these procedures more frequently under severe, dusty, dirty conditions. 2 Have a Kohler authorized dealer perform this service. REPAIRS/SERVICE PARTS Kohler genuine service parts can be purchased from Kohler authorized dealers. To find a local Kohler authorized dealer visit KohlerEngines.com or call 1-800-544-2444 (U.S. and Canada).

4 Maintenance KohlerEngines.com 14 690 01 Rev. G OIL RECOMMENDATIONS We recommend use of Kohler oils for best performance. Other high-quality detergent oils (including synthetic) of API (American Petroleum Institute) service class SJ or higher are acceptable. Select viscosity based on air temperature at time of operation as shown in table below. FUEL RECOMMENDATIONS WARNING Explosive Fuel can cause fires and severe burns. Do not fill fuel tank while engine is hot or running. Gasoline is extremely flammable and its vapors can explode if ignited. Store gasoline only in approved containers, in well ventilated, unoccupied buildings, away from sparks or flames. Spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition. Never use gasoline as a cleaning agent. NOTE: E15, E20 and E85 are NOT approved and should NOT be used; effects of old, stale or contaminated fuel are not warrantable. Fuel must meet these requirements: ● Clean, fresh, unleaded gasoline. ● Octane rating of 87 (R+M)/2 or higher. ● Research Octane Number (RON) 90 octane minimum. ● Gasoline up to 10% ethyl alcohol, 90% unleaded is acceptable. ● Methyl Tertiary Butyl Ether (MTBE) and unleaded gasoline blend (max 15% MTBE by volume) are approved. ● Do not add oil to gasoline. ● Do not overfill fuel tank. ● Do not use gasoline older than 30 days. STORAGE If engine will be out of service for 2 months or more follow procedure below. 1. Add Kohler PRO Series fuel treatment or equivalent to fuel tank. Run engine 2-3 minutes to get stabilized fuel into fuel system (failures due to untreated fuel are not warrantable). 2. Change oil while engine is still warm from operation. Remove spark plug(s) and pour about 1 oz. of engine oil into cylinder(s). Replace spark plug(s) and crank engine slowly to distribute oil. 3. Disconnect negative (-) battery cable. 4. Store engine in a clean, dry place.

5 Specifications 14 690 01 Rev. G KohlerEngines.com ENGINE IDENTIFICATION NUMBERS Kohler engine identification numbers (model, specification and serial) should be referenced for efficient repair, ordering correct parts, and engine replacement. Model ..................... XT-6 Courage Engine Vertical Shaft Numerical Designation Specification ............... XT149-0001 Serial ..................... 4223500328 Year Manufactured Code Factory Code Code Year 42 2012 43 2013 44 2014 GENERAL SPECIFICATIONS 3,6 XT-6, XTR-6 XT6.5, XT650, XT6.75, XT675 XT-7, XTR-7, XT775, XT8 Bore 65 mm (2.6 in.) 70 mm (2.8 in.) Stroke 45 mm (1.8 in.) Displacement 149 cc (9.1 cu. in.) 173 cc (10.6 cu. in.) Oil Capacity (refill) 0.6 L (20 oz.) Maximum Angle of Operation (@ full oil level) 4 20° TORQUE SPECIFICATIONS 3,5 XT-6, XTR-6 XT6.5, XT650, XT6.75, XT675 XT-7, XTR-7, XT775, XT8 Air Cleaner Base Stud Fastener 8 N·m (71 in. lb.) Crankcase Fastener 8 N·m (71 in. lb.) Blower Housing Stud 10 N·m (88 in. lb.) Nut 8 N·m (70 in. lb.) Brake Mounting Fastener 9.5 N·m (84 in. lb.) Breather Cover Fastener 10 N·m (88 in. lb.) Carburetor Stud Fastener 8 N·m (71 in. lb.) 3 Values are in Metric units. Values in parentheses are English equivalents. 4 Exceeding maximum angle of operation may cause engine damage from insufficient lubrication. 5 Lubricate threads with engine oil prior to assembly. 6 Any and all horsepower (hp) references by Kohler are Certified Power Ratings and per SAE J1940 & J1995 hp standards. Details on Certified Power Ratings can be found at KohlerEngines.com.

6 Specifications KohlerEngines.com 14 690 01 Rev. G TORQUE SPECIFICATIONS 3,5 XT-6, XTR-6 XT6.5, XT650, XT6.75, XT675 XT-7, XTR-7, XT775, XT8 Connecting Rod Cap Fastener (torque in increments) 12.5 N·m (110 in. lb.) Crankcase Oil Drain Plug 7 13.6 N·m (120 in. lb.) Oil Pan Screw 11.0 N·m (98 in. lb.) 14.7 N·m (130 in. lb.) Cylinder Head Fastener (torque in 2 increments) first to 14 N·m (123 in. lb.) finally to 27.8 N·m (246 in. lb.) Flywheel Retaining Nut 51.5 N·m (38 ft. lb.) Fuel Tank Bracket to Crankcase Stud 8 N·m (71 in. lb.) Bracket to Tank Fastener 4.5 N·m (40 in. lb.) Governor Lever Fastener 9.5 N·m (84 in. lb.) Gear Fastener 9.5 N·m (84 in. lb.) Ignition Spark Plug 27 N·m (20 ft. lb.) Module Fastener 10 N·m (88 in. lb.) Screw 10 N·m (88 in. lb.) Muffler Exhaust Stud 5.0 N·m (44 in. lb.) Exhaust Stud Nut Fastener 9.5 N·m (84 in. lb.) Retractable Starter Fastener 8 N·m (71 in. lb.) Rocker Arm Stud 13.6 N·m (120 in. lb.) Pivot Jam Nut 9.5 N·m (84 in. lb.) Speed Control Bracket Assembly Fastener 8 N·m (71 in. lb.) Valve Cover Fastener 8 N·m (71 in. lb.) 3 Values are in Metric units. Values in parentheses are English equivalents. 5 Lubricate threads with engine oil prior to assembly. 7 Apply thread sealant around three full threads before assembly. No excess sealant allowed on inside or outside of joint. Threads with preapplied sealant do not require use of additional sealant. Approved sealants include Perma-Loc LH 150, Perma-Loc MM 115, Perma-Loc HH 120, Perma-Loc HL 126.

7 Speciﬁcations 14 690 01 Rev. G KohlerEngines.com CLEARANCE SPECIFICATIONS 3 XT-6, XTR-6 XT6.5, XT650, XT6.75, XT675 XT-7, XTR-7, XT775, XT8 Camshaft End Play 0.3/0.85 mm (0.0118/0.0335 in.) Running Clearance 0.013/0.0555 mm (0.00051/0.00217 in.) Connecting Rod Connecting Rod-to-Crankpin Running Clearance New 0.025/0.045 mm (0.0009/0.0017 in.) Connecting Rod-to-Crankpin Side Clearance New 0.03/0.48 mm (0.00118/0.0189 in.) 0.13/0.58 mm (0.0051/0.0228 in.) Connecting Rod-to-Piston Pin Running Clearance 0.008/0.025 mm (0.0003/0.0009 in.) Piston Pin End I.D. New @ 21°C (70°F) 13.006/13.017 mm (0.5120/0.5125 in.) 18.006/18.017 mm (0.7088/0.7093 in.) Crankcase Governor Cross Shaft Bore I.D. New 6.000/6.024 mm (0.2362/0.2372 in.) Crankshaft End Play (free) 0.427/1.298 mm (0.0168/0.05110 in.) Bore in Oil Pan I.D. Early Models Later Models 25.400/25.421 mm (0.9999/1.0008 in.) 27.050/27.071 mm (1.06496/1.06578 in.) Bore in Oil Pan Running Clearance Early Models Later Models 0.015/0.051 mm (0.0005/0.002 in.) 0.008/0.121 mm (0.0031/0.00476 in.) Bearing (ﬂywheel) Journal O.D. Early Models Later Models Max. Taper Max. Out-of-Round 24.975/24.989 mm (0.9832/0.9838 in.) 25.005/25.019 mm (0.9844/0.9850 in.) 0.025 mm (0.0009 in.) 0.025 mm (0.0009 in.) 24.975/24.989 mm (0.9832/0.9838 in.) 24.975/24.989 mm (0.9832/0.9838 in.) 0.025 mm (0.0009 in.) 0.025 mm (0.0009 in.) Bearing (PTO) Journal O.D. Early Models Later Models Max. Taper Max. Out-of-Round 25.370/25.385 mm (0.9988/0.9994 in.) 26.95/26.97 mm (1.061/1.062 in.) 0.025 mm (0.0009 in.) 0.025 mm (0.0009 in.) Connecting Rod Journal O.D. New Max. Taper Max. Out-of-Round 25.985/25.995 mm (1.0230/1.0234 in.) 0.010 mm (0.0004 in.) 0.010 mm (0.0004 in.) 29.985/29.995 mm (1.1805/1.1809 in.) 0.010 mm (0.0004 in.) 0.010 mm (0.0004 in.) Cylinder Bore Bore I.D. 65.00/65.02 mm (2.559/2.560 in.) 70.00/70.02 mm (2.755/2.756 in.) Max. Out-of-Round Max. Taper 0.0127 mm (0.0005 in.) 0.0127 mm (0.0005 in.) Cylinder Head Max. Out-of-Flatness 0.08 mm (0.003 in.) 3 Values are in Metric units. Values in parentheses are English equivalents.

8 Speciﬁcations KohlerEngines.com 14 690 01 Rev. G CLEARANCE SPECIFICATIONS 3 XT-6, XTR-6 XT6.5, XT650, XT6.75, XT675 XT-7, XTR-7, XT775, XT8 Governor Governor Cross Shaft -to-Crankcase Running Clearance 0.020/0.064 mm (0.0007/0.0025 in.) Cross Shaft O.D. New 5.96/5.98 mm (0.2346/0.2354 in.) Gear Shaft O.D. New 6.01/6.03 mm (0.2366/0.2374 in.) Governor Gear Shaft-to-Governor Gear Running Clearance 0.09/0.19 mm (0.0035/0.0074 in.) Ignition Spark Plug Gap 0.76 mm (0.030 in.) Module Air Gap 0.254 mm (0.010 in.) Piston, Piston Rings, and Piston Pin Pin Bore I.D. 13.002/13.008 mm (0.5118/0.5121 in.) 18.000/18.008 mm (0.7086/0.7089 in.) Pin O.D. 12.990/12.996 mm (0.5114/0.5116 in.) 17.990/17.996 mm (0.7082/0.7085 in.) Top and Center Compression Ring Side Clearance New Bore, Before Serial No. 40244XXXXX New Bore, After Serial No. 40243XXXXX 0.02/0.06 mm (0.0007/0.0023 in.) 0.001/0.020 mm (0.00004/0.00080 in.) Top and Center Compression Ring End Gap New Bore, Before Serial No. 40244XXXXX Top and Center New Bore, After Serial No. 40243XXXXX Top Center 0.25/0.40 mm (0.0098/0.0157 in.) 0.1/0.25 mm (0.0039/0.0098 in.) 0.61/0.76 mm (0.0240/0.0299 in.) 0.25/0.40 mm (0.0098/0.0157 in.) 0.1/0.25 mm (0.0039/0.0098 in.) 0.3/0.5 mm (0.0118/0.0197 in.) Thrust Face O.D. 64.975/64.985 mm (0.2558/0.2558 in.) 69.960/69.980 mm (2.7543/2.7551 in.) Piston Thrust Face-to-Cylinder Bore Running Clearance 0.025/0.035 mm (0.0010/0.0014 in.) 0.020/0.060 mm (0.0007/0.0024 in.) Valves and Valve Lifters Intake and Exhaust Valve Lash 0.0762/0.127 mm (0.003/0.005 in.) Intake Valve Stem-to-Valve Guide Running Clearance 0.020/0.047 mm (0.0007/0.0018 in.) Exhaust Valve Stem-to-Valve Guide Running Clearance 0.055/0.082 mm (0.0021/0.0032 in.) Intake Valve Guide I.D. 5.500/5.512 mm (0.2165/0.2170 in.) Intake Valve Stem Diameter 5.465/5.480 mm (0.2151/0.2157 in.) Exhaust Valve Guide I.D. 5.500/5.512 mm (0.2165/0.2170 in.) Exhaust Valve Stem Diameter 5.430/5.445 mm (0.2137/0.2143 in.) Nominal Valve Face Angle 25°, 45°, 60° 3 Values are in Metric units. Values in parentheses are English equivalents.

9 Speciﬁcations 14 690 01 Rev. G KohlerEngines.com GENERAL TORQUE VALUES Metric Fastener Torque Recommendations for Standard Applications Property Class Noncritical Fasteners Into Aluminum Size 4.8 5.8 8.8 10.9 12.9 Tightening Torque: N·m (in. lb.) ± 10% M4 1.2 (11) 1.7 (15) 2.9 (26) 4.1 (36) 5.0 (44) 2.0 (18) M5 2.5 (22) 3.2 (28) 5.8 (51) 8.1 (72) 9.7 (86) 4.0 (35) M6 4.3 (38) 5.7 (50) 9.9 (88) 14.0 (124) 16.5 (146) 6.8 (60) M8 10.5 (93) 13.6 (120) 24.4 (216) 33.9 (300) 40.7 (360) 17.0 (150) Tightening Torque: N·m (ft. lb.) ± 10% M10 21.7 (16) 27.1 (20) 47.5 (35) 66.4 (49) 81.4 (60) 33.9 (25) M12 36.6 (27) 47.5 (35) 82.7 (61) 116.6 (86) 139.7 (103) 61.0 (45) M14 58.3 (43) 76.4 (56) 131.5 (97) 184.4 (136) 219.7 (162) 94.9 (70) Torque Conversions N·m = in. lb. x 0.113 in. lb. = N·m x 8.85 N·m = ft. lb. x 1.356 ft. lb. = N·m x 0.737 English Fastener Torque Recommendations for Standard Applications Bolts, Screws, Nuts and Fasteners Assembled Into Cast Iron or Steel Grade 2 or 5 Fasteners Into Aluminum Size Grade 2 Grade 5 Grade 8 Tightening Torque: N·m (in. lb.) ± 20% 8-32 2.3 (20) 2.8 (25) — 2.3 (20) 10-24 3.6 (32) 4.5 (40) — 3.6 (32) 10-32 3.6 (32) 4.5 (40) — — 1/4-20 7.9 (70) 13.0 (115) 18.7 (165) 7.9 (70) 1/4-28 9.6 (85) 15.8 (140) 22.6 (200) — 5/16-18 17.0 (150) 28.3 (250) 39.6 (350) 17.0 (150) 5/16-24 18.7 (165) 30.5 (270) — — 3/8-16 29.4 (260) — — — 3/8-24 33.9 (300) — — — Tightening Torque: N·m (ft. lb.) ± 20% 5/16-24 — — 40.7 (30) — 3/8-16 — 47.5 (35) 67.8 (50) — 3/8-24 — 54.2 (40) 81.4 (60) — 7/16-14 47.5 (35) 74.6 (55) 108.5 (80) — 7/16-20 61.0 (45) 101.7 (75) 142.5 (105) — 1/2-13 67.8 (50) 108.5 (80) 155.9 (115) — 1/2-20 94.9 (70) 142.4 (105) 223.7 (165) — 9/16-12 101.7 (75) 169.5 (125) 237.3 (175) — 9/16-18 135.6 (100) 223.7 (165) 311.9 (230) — 5/8-11 149.5 (110) 244.1 (180) 352.6 (260) — 5/8-18 189.8 (140) 311.9 (230) 447.5 (330) — 3/4-10 199.3 (147) 332.2 (245) 474.6 (350) — 3/4-16 271.2 (200) 440.7 (325) 637.3 (470) —

Tools and Aids 10 14 690 01 Rev. G KohlerEngines.com Certain quality tools are designed to help you perform specific disassembly, repair, and reassembly procedures. By using these tools, you can properly service engines easier, faster, and safer! In addition, you’ll increase your service capabilities and customer satisfaction by decreasing engine downtime. Here is a list of tools and their source. SEPARATE TOOL SUPPLIERS Kohler Tools Contact your local Kohler source of supply. SE Tools 415 Howard St. Lapeer, MI 48446 Phone 810-664-2981 Toll Free 800-664-2981 Fax 810-664-8181 Design Technology Inc. 768 Burr Oak Drive Westmont, IL 60559 Phone 630-920-1300 Fax 630-920-0011 TOOLS Description Source/Part No. Alcohol Content Tester For testing alcohol content (%) in reformulated/oxygenated fuels. Kohler 25 455 11-S Camshaft Endplay Plate For checking camshaft endplay. SE Tools KLR-82405 Camshaft Seal Protector (Aegis) For protecting seal during camshaft installation. SE Tools KLR-82417 Cylinder Leakdown Tester For checking combustion retention and if cylinder, piston, rings, or valves are worn. Individual component available: Adapter 12 mm x 14 mm (Required for leakdown test on XT-6 engines) Kohler 25 761 05-S Design Technology Inc. DTI-731-03 Dealer Tool Kit (Domestic) Complete kit of Kohler required tools. Components of 25 761 39-S: Ignition System Tester Cylinder Leakdown Tester Oil Pressure Test Kit Rectifier-Regulator Tester (120 V AC/60Hz) Kohler 25 761 39-S Kohler 25 455 01-S Kohler 25 761 05-S Kohler 25 761 06-S Kohler 25 761 20-S Dealer Tool Kit (International) Complete kit of Kohler required tools. Components of 25 761 42-S: Ignition System Tester Cylinder Leakdown Tester Oil Pressure Test Kit Rectifier-Regulator Tester (240 V AC/50Hz) Kohler 25 761 42-S Kohler 25 455 01-S Kohler 25 761 05-S Kohler 25 761 06-S Kohler 25 761 41-S Digital Vacuum/Pressure Tester For checking crankcase vacuum. Individual component available: Rubber Adapter Plug Design Technology Inc. DTI-721-01 Design Technology Inc. DTI-721-10 Electronic Fuel Injection (EFI) Diagnostic Software For Laptop or Desktop PC. Kohler 25 761 23-S EFI Service Kit For troubleshooting and setting up an EFI engine. Components of 24 761 01-S: Fuel Pressure Tester Noid Light 90° Adapter In-line "T" Fitting Code Plug, Red Wire Code Plug, Blue Wire Shrader Valve Adapter Hose Kohler 24 761 01-S Design Technology Inc. DTI-019 DTI-021 DTI-023 DTI-035 DTI-027 DTI-029 DTI-037 Flywheel Puller For properly removing flywheel from engine. SE Tools KLR-82408

Kohler XT675 Engine Full Service Repair Manual

You're Reading a Preview

Recently Viewed